Flexible non-woven mat

ABSTRACT

A non-woven fibrous mat is provided that includes a mixture of a thermoset resin and a thermoplastic resin. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a binder composition comprising variable ratios of the thermoset material and the thermoplastic material. In this way, a bonded nonwoven mat may be achieved having a desirable combination of strength and flexibility, while maintaining good heat and water resistance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Application No. 62/868,211, filed Jun. 28, 2019, the entire content of which is incorporated by reference herein.

FIELD

The present invention relates to non-woven fibrous mats with an enhanced combination of strength and flexibility, and methods of manufacturing such non-woven fibrous mats.

BACKGROUND

Conventional non-woven mats include a web of fibers bound together by a suitable resinous binder. Reinforcement fibers, such as glass fibers, are useful in a variety of technologies, and may be used in the form of continuous or chopped filaments, strands, rovings, woven fabrics, nonwoven fabrics, meshes, and scrims (also called mats and veils), useful for reinforcing a number of materials.

Fibrous glass mats provide good insulative properties and dimensional stability as they generally do not shrink or stretch in response to changes in atmospheric conditions. Further, glass fibers have high tensile strength, heat resistance, moisture resistance, and high thermal conductivity. These properties make glass fiber mats a common choice for insulation of equipment that is exposed to changes in heat and/or humidity, such as HVAC ductwork. However, the resinous binders that are commonly used to manufacture such duct insulation can substantially alter the ability of the fibrous mat to withstand the environmental fluctuations associated with HVAC applications. Moreover, as HVAC duct work can take many unique configurations, the fibrous mat must balance flexibility and strength, while continuing to provide excellent insulation.

Therefore, a need exists for a non-woven mat that is flexible enough to be formed into appropriate shapes and is lightweight yet has sufficient strength properties such that it can be used satisfactorily in environmentally diverse applications.

SUMMARY

The general inventive concepts are based, in part, on the discovery that a fibrous mat comprising a binder composition with a combination of a thermoset(ting) resin and a thermoplastic resin can provide a nonwoven mat having an enhanced combination of flexibility, strength, and heat/humidity resistance. In certain exemplary embodiments, the binder composition is applied to the nonwoven mat in one or more stages including a first binder composition providing one or more of tensile strength, heat resistance, and hot water resistance, and a second binder composition providing one or more of flexibility and smoothness to the ultimate product. When applied in stages, the second binder composition may form a “shell” around the “core” first binder composition.

In certain exemplary embodiments, a first binder composition (also referred to as a precursor binder) is applied to a nonwoven mat to form a precursor mat, followed by application of a second binder composition (also referred to as a coating binder), wherein the resin that forms the first binder composition is selected from a thermoset polymer a thermoplastic polymer, and combinations thereof, and wherein, when the first resin comprises a thermoset polymer the second binder resin comprises a thermoplastic polymer and when the first resin comprises a thermoplastic polymer the second binder resin comprises a thermoset polymer.

In certain exemplary embodiments, a thermosetting material is applied to a nonwoven mat, followed by application of a thermoplastic material.

In certain exemplary embodiments, the physical properties of a non-woven fibrous mat are improved by formulating a binder composition combining a binder that provides heat and hot water resistance with a binder that provides enhanced flexibility.

In certain exemplary embodiments, a bonded non-woven mat is provided. The mat comprising: a nonwoven fiber web; and a binder composition comprising a mixture of a thermoset material and a thermoplastic material. The thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder composition. The bonded non-woven mat has a Gurley stiffness of 500 mg to 2000 mg.

In certain exemplary embodiments, a method of forming a bonded non-woven mat is described. The method comprises providing a fibrous web; applying a precursor binder composition to the fibrous web to form a precursor web; applying a coating binder composition to the precursor web; and allowing the nonwoven mat to cure; wherein the bonded nonwoven mat has a Gurley stiffness of 500 mg to 2000 mg. At least one of the precursor binder and the coating binder is a thermoset material and at least one of the precursor binder and the coating binder is a thermoplastic material. The thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder composition. When the first resin comprises a thermoset polymer (material) the second binder resin comprises a thermoplastic polymer (material) and when the first resin comprises a thermoplastic polymer the second binder resin comprises a thermoset polymer.

Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying FIGURES.

BRIEF DESCRIPTION OF THE DRAWINGS

The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

FIG. 1 shows an illustration of a core/shell binder combination, in principle.

DETAILED DESCRIPTION

Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

As used herein, unless otherwise indicated, the terms “surface modifier” and “modifying agent” are used interchangeably and refer to a chemical agent applied to the surface of a glass fiber in the absence of a binder. The surface modifier is provided generally to protect the surface of the glass from unwanted physical and/or chemical interaction.

The term “binder formulation” as used herein refers to a combination of a first binder resin and a second binder resin, according to the general inventive concepts. In certain embodiments, the term refers to the total binders including thermoset (one or more) resin(s) and thermoplastic (one or more) resin(s).

The term “thermoplastic material,” “thermoplastic polymer,” or “thermoplastic resin” as used herein refer to resins or binders that, after curing, become pliable or moldable when heated above a certain temperature. Suitable thermoplastic resins for use according to the general inventive concepts include those having a glass transition temperature of −30° C. to 40° C. Examples of suitable resins include: Acronal NX 4569, Acronal NX 4787, Acronal NX4612, Acronal NX 3587 and Acronal 4250 from BASF; Rhplex NW-1845K from Dow Chemical; DUR-O-SET ELITE 22 and DUR-O-SET E-646 Emulsion from Celanese. The thermoplastic material provides the softness needed for flexible mats.

The term “thermoset material,” “thermoset polymer,” or “thermoset resin” as used herein refer to resins or resins or binders that are irreversibly hardened by curing. Examples of suitable resins include: acrylic resins, Joncryl 540, Joncryl 1540, Luhydran A 848 S, Acordur 950L, Acrodur DS3515 from BASF; Aquaset 100, QR-16295 from Dow chemical.

While various exemplary embodiments are described or suggested herein, other exemplary embodiments utilizing a variety of methods and materials similar or equivalent to those described or suggested herein are encompassed by the general inventive concepts.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. In this connection, unless otherwise indicated, concentrations of ingredients given in this document refer to the concentrations of these ingredients in the master batch or concentrate, in keeping with customary practice.

The general inventive concepts are based, in part, on the discovery that a fibrous mat (also called a bonded fibrous mat) comprising a binder formulation with a combination of thermoplastic resin(s) and thermosetting resin(s) can provide a nonwoven mat having an enhanced combination of flexibility, strength, and heat/humidity resistance. In certain exemplary embodiments, the binder composition is applied to the nonwoven mat in one or more stages. When applied in stages, the second binder composition may form a “shell” around the “core” first binder composition.

The general inventive concepts relate to a flexible non-woven fibrous mat (generally, the non-woven mat) with improved properties. In some exemplary embodiments, the flexible non-woven mat demonstrates improved mechanical strength, such as high tensile strength, while also showing improved flexibility and smoothness. The softness and flexibility of the inventive non-woven mats facilitate its use in duct board (e.g., HVAC) and

RELATED APPLICATIONS

The glass fibers used to form the inventive mats may be made of any suitable raw materials. For example, the glass fibers may be produced from a variety of natural minerals or manufactured chemicals such as silica sand, limestone, and soda ash. Other ingredients may include calcined alumina, borax, feldspar, nepheline syenite, magnesite, and kaolin clay. The method of forming the fibers from the raw glass material (fiberization) is generally known in the art. The fibers once formed, may be pulverized, cut, chopped or broken into suitable lengths for various applications.

The fibrous mats according to the general inventive concepts may take a variety of forms according to their intended use. In certain exemplary embodiments, the fibrous mats may comprise only one type of fiber. In certain exemplary embodiments, the fibrous mat according to the general inventive concepts is formed with a mixture of two types of fiber, including glass fibers. In certain exemplary embodiments, the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 9-11 microns. In certain exemplary embodiments, the fibrous mat is formed by a combination of fiberglass having a diameter of 13 microns and a fiberglass having a diameter of 9-11 microns. In certain exemplary embodiments, the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 11 microns. In certain exemplary embodiments, the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 10 microns. In certain exemplary embodiments, the fibrous mat may comprise the combination of fiberglass in a ratio of 10:1 to 1:10 by weight, including a ratio of about 1:1 by weight.

The flexible non-woven mats of the present invention may comprise a plurality of fibers, including any of glass fibers, synthetic fibers, or a blend thereof. In certain exemplary embodiments, the mats include only glass fibers. The glass fibers can be made from any type of glass. Examples of glass fibers include A-type glass fibers, C-type glass fibers, E-type glass fibers, S-type glass fibers, ECR-type glass fibers (e.g., Advantex® glass fibers commercially available from Owens Corning), Hiper-tex™, wool glass fibers, and combinations thereof. The use of other reinforcing fibers such as mineral fibers, carbon fibers, ceramic fibers, natural fibers (e.g., cellulosic), and/or synthetic fibers in the non-woven mat is also considered to be within the purview of the general inventive concepts.

The glass fibers may be formed by conventional methods known to those skilled in the art. For example, the glass fibers may be formed by a continuous manufacturing process in which molten glass passes through the holes of a “bushing,” the streams of molten glass thereby formed are solidified into filaments, and the filaments are combined together to form a fiber, “roving,” “strand,” or the like.

After the glass fibers are drawn from the bushing, an aqueous sizing composition (also referred to as a size) may optionally be applied to the fibers. The sizing composition is not limited, and may be any sizing known to those of skill in the art. Generally sizing compositions contain a lubricant to protect the fibers from damage by abrasion. The sizing composition may be applied by conventional methods such as by an application roller or by spraying the size directly onto the fibers. The size protects the glass fibers from breakage during subsequent processing, helps to retard interfilament abrasion, ensures the integrity of the strands of glass fibers, promotes the interconnection of the glass filaments that form the strand, etc.

After the glass fibers are treated with the sizing composition, they may be chopped for subsequent processing into a wet-laid, non-woven mat as described below. In certain exemplary embodiments, the chopped fibers may have a length from about 0.2 to about 2.0 inches, including from about 0.6 to about 1.5 inches. The chopped fibers may have varying lengths from each other within the non-woven mat.

These fibers are then coated with a first binder composition to form a fiberglass mat (also called a precursor binder composition and the resulting precursor mat) that can then pass to a coating station (the term coating also encompasses impregnation) with a second binder composition (i.e., a coating binder composition) detailed below. Thus, the subject process is a two-step process.

The flexible non-woven mat may be formed by a variety of processes, including dry-laid and wet-laid processes. In certain exemplary embodiments, the non-woven mat is formed by a wet-laid process, which involves forming an aqueous dispersion or slurry of discrete fibers in a mix tank filled with various components (sometimes referred to as white water), such as water, surfactants, viscosity modifiers, defoaming agents, lubricants, biocides, and/or other chemical agents, along with agitation, to form a glass fiber slurry. It is desirable that the slurry is agitated sufficiently to provide a uniform or nearly uniform dispersion of fibers.

The aqueous fiber dispersion or slurry may then be processed into a wet-laid mat according to any number of conventional methods known in the art. For example, the aqueous fiber slurry is deposited onto a moving screen or conveyor, on which the majority of the water drains through, leaving a randomly oriented fiber web. The fiber web may be further dried by a vacuum slot or other drying means to provide a fiber web.

A first binder composition (also referred to herein as a precursor binder) may then be applied to the fiber web in a conventional manner, such as by curtain coating, spraying, a twin wire dip bath, a two roll padder, and the like. Water, excess binder, and excess coupling agent may then be removed by a vacuum or other water removal means. In certain embodiments, the precursor composition also includes a mixture of components that impart additional functional and/or aesthetic features to the final fibrous mat. These include pigments, flame retardants, fillers, etc. Finally, the binder-coated fiber web or mat may be dried and allowed to cure. In certain instances, the binder is cured by means of an oven. This dried and cured fibrous mat is referred to herein as a precursor mat. In certain embodiments, the first binder composition comprises only one binder resin. In certain exemplary embodiments, the first binder composition may comprise more than one type of binder resin (e.g., both a thermosetting resin and a thermoplastic resin, or more than one thermosetting resin). In certain exemplary embodiments, the precursor binder composition comprises a thermoset material and a thermoplastic material in a ratio of 5:1 to 1:5 by weight, including a ratio of 2:1 to 1:2. In certain exemplary embodiments, the precursor binder composition is present in the bonded fibrous mat in an amount of 2 g/m² to 6 g/m². In certain exemplary embodiments, the precursor binder composition is present in the bonded fibrous mat in an amount of 2.5 g/m² to 5 g/m². In certain exemplary embodiments, the precursor binder composition is present in the bonded fibrous mat in an amount of 3 g/m² to 4 g/m².

It has been discovered that formulating a binder composition that incorporates binder resins with differing functionalities (e.g., thermoset and thermoplastic) may impart improved properties to the bonded fibrous mat. In particular, the combination of such properties may allow the non-woven mats to be used in challenging applications, such as applications where exposure to high temperature and humidity are common.

A second binder composition (also referred to as a coating binder composition) may then be applied to the precursor mat in an appropriate manner, including a process similar to that discussed for the first binder composition. The coating is a mixture of components that impart additional functional and/or aesthetic features to the final fibrous mat. These include pigments, flame retardants, viscosity modifiers (for improved application of the coating), biocides, etc, and generally include an additional adhesive or binder to adhere the impregnation components to the mat. One form of a coating composition is an impregnation. In certain embodiments, the second binder composition comprises only one binder resin. In certain exemplary embodiments, the second binder composition may comprise more than one binder resin (e.g., both a thermosetting binder and a thermoplastic resin, or more than one thermosetting binder). In certain exemplary embodiments, the coating binder composition is present in the bonded fibrous mat in an amount of 2 g/m² to 8 g/m². In certain exemplary embodiments, the coating binder composition is present in the bonded fibrous mat in an amount of 3 g/m² to 6 g/m². In certain exemplary embodiments, the coating binder composition is present in the bonded fibrous mat in an amount of 3.5 g/m² to 5.5 g/m².

In accordance with various aspects of the present invention, the binder formulation is formulated such that once the binder is cured, it is able to impart enhanced mechanical strength (e.g., total tensile strength), coupled with excellent flexibility (e.g., Gurley stiffness of less than 2000 mg), among other desirable properties. The general inventive concepts are based, in part, on the discovery that the enhanced combination of flexibility and strength may be attained by tuning the amount of thermoplastic material (i.e., coating or impregnation binder) relative to thermoset material (e.g., precursor binder). While not wishing to be bound by theory, it is believed that the thermoset resin provides excellent stiffness and heat resistance, while the thermoplastic resin provides flexibility and smoothness. In certain exemplary embodiments, the binder formulation comprises a mixture of a thermoset material and a thermoplastic material, wherein the thermoplastic material is present in an amount of greater than 50% of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a mixture of a thermoset material and a thermoplastic material, wherein the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 10% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 90% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 20% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 80% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 30% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 70% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 40% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 60% by weight of the total binder formulation.

The thermoset material may comprise, for example, an acrylic material. In some exemplary embodiments, the acrylic material is Joncryl 540, Joncryl 1540, Luhydran A 848 S, Acordur 950L, Acrodur DS3515 from BASF; Aquaset 100, QR-1629S from Dow chemical. The thermoset material, once cured, provides good tensile performance and heat/water resistance helping maintain mat integrity in different applications. The thermoplastic material provides good flexibility and smoothness helping maintain desirable aesthetic and functional characteristics in different applications. In some exemplary embodiments, the thermoplastic material may include any thermoplastic material having a low Tg (i.e., below 10° C.), for example, below 0° C.

As mentioned, the general inventive concepts contemplate a non-woven mat having improved mechanical strength. In certain exemplary embodiments, the flexible non-woven mats have an average tensile strength of at least 70 N/50 mm in the machine direction (MD) and at least 35 N/50 mm in the cross direction (CD). In certain exemplary embodiments, the flexible non-woven mats have a machine direction tensile strength of at least 90 N/50 mm and a cross-direction tensile strength of at least 54 N/50 mm. The flexible non-woven mats may further have a total tensile strength (machine direction+cross-direction) of at least 105 N/50 mm, or at least 23 lb/2 inch.

The general inventive concepts contemplate a flexible non-woven mat. In certain exemplary embodiments, the non-woven mats demonstrate a Gurley stiffness of less than 2000 mg, including 500 to 2000, and including 1000 mg to 2000 mg.

The binder formulation may optionally include additional components, for example, coupling agents, dyes, oils, fillers, colorants, aqueous dispersions, UV stabilizers, lubricants, biocide, wetting agents, surfactants, viscosity modifiers, and/or antistatic agents. The aqueous dispersions may include antioxidant dispersions, which counter the effects of oxidation by the binder composition due to aging.

In accordance with some exemplary embodiments, the binder formulation further includes water to dissolve or disperse the components for application onto the reinforcement fibers. Water may be added in an amount sufficient to dilute the aqueous binder composition to a viscosity that is suitable for its application to the fiber web.

The bonded fibrous mats of the present invention may have an average thickness of between about 0.25 and 1.00 millimeters, or from about 0.50 to about 0.70 millimeters.

The bonded nonwoven fibrous mats according to the general inventive concepts can be formulated to have a variety of properties such as total weight. In certain exemplary embodiments, the bonded non-woven fibrous mat has a total weight of between 30 g/m² and 100 g/m². In certain exemplary embodiments, the bonded non-woven fibrous mat has a total weight of between 55 g/m² and 75 g/m². In certain exemplary embodiments, the bonded non-woven fibrous mat has a total weight of about 62 g/m². In certain exemplary embodiments, the total weight of glass fibers in the bonded non-woven fibrous mat is between 25 g/m² and 80 g/m². In certain exemplary embodiments, the total weight of glass fibers in the bonded non-woven fibrous mat is between 40 g/m² and 55 g/m². In certain exemplary embodiments, the total weight of glass fibers in the bonded non-woven fibrous mat is about 48 g/m².

Incorporating a soft, but strong binder composition, in combination with the proper blend of glass, produces a flexible non-woven mat with an improved combination of flexibility and strength. The flexible non-woven mats may be used in a variety of downstream processes to form a variety of end products. In some exemplary embodiments, the flexible non-woven mat is used to form a composite product or an insulation board, for example.

Having generally introduced the general inventive concepts by disclosing various exemplary embodiments thereof, a further understanding can be obtained by reference to certain specific examples illustrated below which are provided for purposes of illustration only and are not intended to be all inclusive or otherwise limiting of the general inventive concepts.

EXAMPLES Example 1

Non-woven mats were made by a conventional wet laid coating process in which chopped glass fibers, after being deposited onto a moving screen in the form of an aqueous slurry, were coated with an aqueous dispersion of a binder composition (also referred to as a precursor binder) and then dried and cured. All mats were made with 0.75″ K fiber (13 micrometer diameter) and cured at 210° C. The machine direction (MD) and cross direction (CD) tensile strengths of the nonwovens were tested using an Instron machine.

TABLE 1 Binder weight = 5.0 g/m²; Glass weight = 48 g/m² Tensile Gurley strengths stiffness Sample Precursor Binder (MD + CD) (MD + CD) Sample 1 Dow 1- TS 131N 1058 mgf Sample 2 Dow 2 - TS 136N 1101 mgf Sample 3 Dow 2 - TS/BASF 1 - TP 124N 1150 mgf (75:25)

Dow 1—TS and Dow 2—TS are thermosetting resins supplied from Dow Chemical. BASF 1—TP is thermoplastic resin (Tg 23° C.) supplied by BASF.

Each mat in Table 1 was made with the same precursor binder weight and glass weight. (Precursor binder weight and glass weight were calculated from base weight and Loss on ignition (LOI)). As shown in Table 1, non-woven mats with 100% thermosetting resin (Sample 1 and Sample 2) showed Gurley stiffness around 1100 mg. To reduce Gurley stiffness, 25% of thermoplastic resin (BASF 1—TP) was blended with 75% of thermosetting resin (Dow 2—TS). However, Sample 3 mats with this blended precursor binder option did not show Gurley stiffness reduction.

TABLE 2 Binder weight = 3.5 g/m²; Glass weight = 48 g/m² Tensile Gurley strengths stiffness Sample Precursor Binder (MD + CD) (MD + CD) Sample 4 Dow 1- TS 84 741 mgf Sample 5 Dow 2 - TS 93 768 mgf

Table 2 shows the results of physical property characteristics for two samples made with thermosetting materials. To reduce Gurley stiffness, precursor binder weights were decreased from 4.5 g/m² to 3.5 g/m². Dow 1—TS and Dow 2—TS were used as precursor binder for sample 4 and sample 5, respectively. As a result, Gurley stiffness went down with reduction of binder weight. For example, Gurley stiffness reduced from 1101 mg to 758 mg, when binder weight of Dow 2—TS decreased from 5.0 g/m² (Sample 2) to 3.5 g/m² (Sample 5). Tensile strengths were also decreased as expected, due to binder reduction.

Example 2: (Samples Prepared by Lab Scale Impregnator)

Non-woven mat with Dow 2—TS (Sample 5) in Table 2 served as precursor for the study of impregnation binders. A lab scale impregnator was used in this study. Thermoplastic resins with varying glass transition temperature (Tg) were selected as impregnation formulation (Table 3). Impregnated non-woven veils were dried/cured at 150° C. for 3 min.

TABLE 3 Impregnation Add-on weight: 5 g/m² Tensile Gurley Impregnation strengths stiffness Sample formulation Tg (MD + CD) (MD + CD) Sample 6 Arkema 1 - TP 20° C. 183N 1625 mgf Sample 7 BASF 2 - TP  4° C. 142N 1045 mgf Sample 8 BASF 3 - TP −5° C. 156N  925 mgf Sample 9 BASF 4 - TP −21° C.  128N  810 mgf

Gurley stiffness values decrease along with Tg of the impregnation resins. This is an important feature. By adjusting the impregnation formulation by varying the Tg of resins, the stiffness of impregnated non-woven veils can be tuned (from 810 to 1625 mgf). Tensile strengths for sample 6 to sample 9 are all higher than sample 5 (precursor non-woven mat with Dow 2—TS ACR) due to impregnation resins. This suggests that impregnated non-woven veils can be adjusted to designed range of Gurley stiffness and tensile strength by changing types and add-on weights of thermoplastic resins.

Example 3: (Samples Prepared by Production Run)

In this Example, impregnated non-woven mats were prepared for insulation applications. Besides thermoset(ting) and thermoplastic materials (e.g., resins), carbon black and aluminum trihydrate (ATH) were added into mat recipes as colorant and flame retardant, respectively.

TABLE 4 Comparative Comparative Recipe Raw Material Sample 10 Sample 11 Sample 12 Glass 13 um-19 mm 24 g/m² 24 g/m² 24 g/m² 11 um-19 mm 24 g/m² N/A 24 g/m² 10 um-10 mm N/A 24 g/m² N/A Precursor Thermosetting binder N/A 4.5 g/m² 3.2 g/m² formulation Thermoplastic resin Tg 7.5 g/m² N/A N/A 10° C. Colorant and Carbon black and 5 g/m² 5 g/m² 5 g/m² Flame ATH retardant* Impregnation Thermoplastic resin N/A 3.7 g/m² 5.2 g/m² formulation Tg-20° C. Additives Antifoam, viscosity <0.5 g/m² <0.5 g/m² <0.5 g/m² modifier etc *Colorant and flame retardant can be blend with either precursor binder or impregnation formulation

Sample 10 was made in a single-step preparation (no impregnation). To prepare Sample 10, thermoplastic material (Tg 10° C.), carbon black and ATH were blended together as precursor formulation, which applied through wet laid coating process. In sample 11 and sample 12, thermosetting material functionalized as precursor formulation applied to glass fiber by wet laid coating process, while thermoplastic material, colorant and flame retardant are blended together as impregnation formulation, which applied by impregnation process.

TABLE 5 Thermo- Gurley Tensile Hot- Hot- setting stiffness strengths dry* wet** vs Thermo- (MD + (MD + tensile tensile Sample plastic CD) CD) (MD) (MD) Comparative  0:100 1510 220N 27N 51N Sample 10 Comparative 56:44 1825 212N 98N 74N Sample 11 Sample 12 41:59 1470 207N 86N 75N *Hot-wet tensile test: Samples were immerged in 80° C. water for 10 min. Take samples out and dry them by paper towel, following by tensile test. **Hot-dry tensile test: Tensile test when samples being heated to 120° C.

Sample 10: (Current version −1)100% thermoplastic material (Tg 10° C.) blended with carbon black and ATH

Sample 11: (Current version −2)>50% of thermosetting binder as precursor binder; <50% of thermoplastic material (Tg −20° C.) blended with carbon black and ATH

Sample 12: (New version)<50% of thermosetting binder as precursor binder; >50% of thermoplastic material (Tg −20° C.) blend with carbon black and ATH

Sample 10 and Sample 12 showed similar Gurley stiffness (need to control thermosetting material <50%, if not, such as Sample 11 showing higher Gurley stiffness).

All samples showed similar tensile strengths.

Sample 12 (and Sample 11) showed better performance for hot-dry and hot-wet tensile strengths vs. Sample 10 because of thermosetting material in recipes.

All percentages, parts and ratios as used herein, are by weight of the total composition, unless otherwise specified. All such weights as they pertain to listed ingredients are based on the active level and, therefore, do not include solvents or by-products that may be included in commercially available materials, unless otherwise specified.

All references to singular characteristics or limitations of the present disclosure shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made.

All combinations of method or process steps as used herein can be performed in any order, unless otherwise specified or clearly implied to the contrary by the context in which the referenced combination is made.

All ranges and parameters, including but not limited to percentages, parts, and ratios, disclosed herein are understood to encompass any and all sub-ranges assumed and subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more (e.g., 1 to 6.1), and ending with a maximum value of 10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.

The fiberglass compositions, and corresponding manufacturing methods of the present disclosure can comprise, consist of, or consist essentially of the essential elements and limitations of the disclosure as described herein, as well as any additional or optional ingredients, components, or limitations described herein or otherwise useful in fiberglass composition applications.

The fiberglass compositions of the present disclosure may also be substantially free of any optional or selected essential ingredient or feature described herein, provided that the remaining fiberglass composition still contains all of the required ingredients or features as described herein. In this context, and unless otherwise specified, the term “substantially free” means that the selected composition contains less than a functional amount of the optional ingredient, typically less than 0.1% by weight, and also including zero percent by weight of such optional or selected essential ingredient.

To the extent that the terms “include,” “includes,” or “including” are used in the specification or the claims, they are intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B), it is intended to mean “A or B or both A and B.” When the Applicant intends to indicate “only A or B but not both,” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

In some embodiments, it may be possible to utilize the various inventive concepts in combination with one another. Additionally, any particular element recited as relating to a particularly disclosed embodiment should be interpreted as available for use with all disclosed embodiments, unless incorporation of the particular element would be contradictory to the express terms of the embodiment. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the disclosure, in its broader aspects, is not limited to the specific details presented therein, the representative apparatus, or the illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concepts.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It should be understood that only the exemplary embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. 

1-20. (canceled)
 21. A bonded non-woven mat comprising: a nonwoven fiber web; and a binder formulation comprising a mixture of a thermoset material and a thermoplastic material, wherein the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder formulation, and wherein the bonded non-woven mat has a Gurley stiffness of 500 mg to 2000 mg.
 22. The bonded non-woven mat of claim 21, wherein the bonded non-woven mat has a Gurley stiffness of 1000 mg to 2000 mg.
 23. The bonded non-woven mat of claim 21, wherein the bonded non-woven mat has a tensile strength (MD+CD) of at least 105 N/50 mm.
 24. The bonded non-woven mat of claim 21, wherein the thermoset material and the thermoplastic material are present in a ratio of 4:1 to 1:4 by weight.
 25. The bonded non-woven mat of claim 24, wherein the thermoset material and the thermoplastic material are present in a ratio of 2:1 to 1:2.
 26. The bonded non-woven mat of claim 21, wherein the thermoset material comprises part of a precursor binder and the coating binder composition includes a second resin component.
 27. The bonded non-woven mat of claim 21, wherein the thermoset material comprises part of a precursor binder and the precursor binder composition is present in the bonded fibrous mat in an amount of 2 g/m² to 6 g/m².
 28. The bonded non-woven mat of claim 27, wherein the precursor binder composition is present in the bonded fibrous mat in an amount of 2.5 g/m² to 4.5 g/m².
 29. The bonded non-woven mat of claim 21, wherein the thermoplastic material comprises a coating binder and the coating binder is present in the bonded fibrous mat in an amount of 2 g/m² to 8 g/m².
 30. The bonded non-woven mat of claim 29, wherein the coating binder is present in the bonded fibrous mat in an amount of 3.5 g/m² to 5.5 g/m².
 31. The bonded non-woven mat of claim 21, wherein the thermoset material is present in an amount of 30% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 70% by weight of the total binder formulation.
 32. The bonded non-woven mat of claim 21, wherein the thermoset material is present in an amount of 40% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 60% by weight of the total binder formulation.
 33. A method of forming a bonded non-woven mat comprising: providing a fibrous web; applying a precursor binder composition to the fibrous web to form a precursor web; applying a coating binder composition to the precursor web; and allowing the nonwoven mat to cure to form a bonded nonwoven mat; wherein the bonded nonwoven mat has a Gurley stiffness of 500 mg to 2000 mg.
 34. The method of claim 33, wherein the precursor binder composition comprises a thermoset material.
 35. The method of claim 34, wherein the coating binder composition comprises a thermoplastic material.
 36. The method of claim 35, wherein the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder formulation.
 37. The method of claim 33, wherein the bonded nonwoven mat has a tensile strength (MD+CD) of at least 105 N/50 mm after curing.
 38. The method of claim 34, wherein the thermoset material is present in the bonded nonwoven mat in an amount of 2 g/m² to 6 g/m².
 39. The method of claim 35, wherein the thermoplastic material is present in the bonded nonwoven mat in an amount of 2 g/m² to 8 g/m².
 40. The method of claim 33, wherein fibrous web comprises fiberglass and the total weight of fiberglass in the bonded non-woven mat is between 40 g/m² and 60 g/m². 